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General calibration method of cutter runout and cutting force coefficients for flat-end cutter and its using for cutting force prediction during peripheral milling

[+] Author and Article Information
Xing Zhang

State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi Province, P.R. China, 710054
xingzhang2413@gmail.com

Wei Zhang

State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi Province, P.R. China, 710054
zhangwei-lyt@foxmail.com

Jun Zhang

State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi Province, P.R. China, 710054
junzhang@mail.xjtu.edu.cn

Bo Pang

State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi Province, P.R. China, 710054
287766156@qq.com

Wanhua Zhao

State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi Province, P.R. China, 710054
whzhao@xjtu.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4038371 History: Received March 31, 2017; Revised October 31, 2017

Abstract

A general calibration method of cutter runout and specific cutting force coefficients (SCFCs) for flat-end cutter is proposed in this paper, and a high accuracy of cutting force prediction during peripheral milling is established. In the paper, the cutter runout, the bottom edge cutting effect and the actual federate with limitation during large tool path curvature are concerned comprehensively. Firstly, based on the trochoid motion, a tooth trajectory model is built up and an analytical instantaneous uncut chip thickness (IUCT) model is put forward for describing the cutter/workpiece engagement (CWE). Secondly, a non-contact identification method for cutter runout including offset and inclination is given, which constructs an objective function by using the cutting radius relative variation between adjacent teeth, and identifies through a numerical optimization method. Thirdly, with consideration of bottom edge cutting effect, the paper details a three-step calibration procedure for SCFCs based on an enhanced thin plate milling experiment. Lastly, a series of milling tests are performed to verify the effectiveness of the proposed method. The results show that the approach is suitable for both constant and non-constant pitch cutter, and the generalization has been proved. Moreover, the paper points out that the cutter runout has a strong spindle speed dependent effect, the milling force in cutter axis direction exists a switch-direction phenomenon, and the actual federate will be limited by large tool path curvature. All of them should be considered for obtaining an accurate milling force prediction.

Copyright (c) 2017 by ASME
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